Corner lock tray and blank therefor

ABSTRACT

A container formed from a blank of sheet material includes a bottom panel, first end panel, and first side panel that together form a first corner of the container. The first corner is secured by a first corner locking member. The first corner locking member is struck in part from a first corner flap and in part from the first side panel. The first corner locking member is hingedly connected to the first corner flap along a first fold line. The first corner locking member is inserted through a slot formed through the first end panel and into a first corner aperture formed through the first side panel, wherein the first corner aperture is formed by folding the first corner locking member out of plane with the first side panel.

REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 62/443,025 filed on Jan. 6, 2017, which is hereby incorporated by reference in its entirety.

BACKGROUND

The field of the invention relates generally to containers and blanks and more specifically to hand set trays and blanks.

Current hand set trays suffer from certain limitations. For example, they may be difficult to construct, may lack corner strength, may have a tendency to not retain their shape under load, may be aesthetically unpleasing, may produce an undesirable amount of blank waste material, may require an excessive amount of blank material to form, and/or may require the use of a blank with an undesirably large footprint. Accordingly, it is an object of at least one aspect of the present invention to provide a tray and blank therefor that solve or mitigate the problems associated with the prior art.

SUMMARY

According to a first aspect of the invention, there is provided a container formed from a blank of sheet material. The container includes a bottom panel forming a bottom wall of the container. The container further includes a first end panel extending upwardly from a first end edge of the bottom panel and forming a first end wall of the container. The container further includes a first side panel extending upwardly from a first side edge of the bottom panel and forming a first side wall of the container. The first end panel, first side panel, and bottom panel together form a first corner of the container. The container further includes a first corner flap hingedly connected to the first side panel along a first end edge thereof. The first corner flap is disposed in face-contacting relationship with the first end panel. The container further includes a first corner locking member securing the first corner. The first corner locking member is struck in part from the first corner flap and in part from the first side panel. The first corner locking member is hingedly connected to the first corner flap along a first fold line. The first corner locking member is inserted through a slot formed through the first end panel and into a first corner aperture formed through the first side panel that is formed by folding the first corner locking member out of plane with the first side panel.

Optionally, the container further includes second, third, and fourth corner locking members securing respective second, third, and fourth corners of the container.

Optionally, the first corner locking member includes a bridge portion defined between the first fold line and a second fold line. The bridge portion has a height that is at least about equal to a thickness of the blank of sheet material.

Optionally, the first corner locking member further includes a generally-rectangular locking tab that is inserted into the first corner aperture.

Optionally, the first corner locking member further includes an intermediate portion disposed between the bridge portion and the locking tab. The intermediate portion is generally trapezoidal in shape. The intermediate portion is disposed in face-contacting relationship with an interior surface of the first end panel.

Optionally, the first slot has a generally elongated rectangular shape. The first slot has a width that is at least about equal to the thickness of the blank of sheet material. The first slot has a height that is at least about equal to a greatest width of the first corner locking member.

According to a second embodiment, a blank of sheet material for forming a container is provided. The blank includes a bottom panel having first and second opposing end edges and first and second opposing side edges extending between the end edges. The bottom wall panel is configured to form a bottom wall in a set-up container. The blank further includes a first end panel hingedly connected to the bottom panel along the first end edge. The first end panel is configured to form a first end wall in the set-up container. The blank further includes a first side panel hingedly connected to the bottom panel along the first side edge. The first side panel is configured to form a first side wall in the set-up container. The first end wall, first side wall, and bottom wall together form a first corner in the set-up container. The blank further includes a first corner flap hingedly connected to the first side panel along a first end edge thereof. The first corner flap is configured to fold into face-contacting relationship with the first end panel in the set-up container. The first corner locking member is configured to secure the first corner in the set-up container. The first corner locking member is struck in part from the first corner flap and in part from the first side panel. The first corner locking member is hingedly connected to the first corner flap along a first fold line. In the set-up container, the first corner locking member passes through a slot formed through the first end panel and into a first corner aperture formed through the first side panel, wherein the first corner aperture results from folding the first corner locking member out of plane with the first side panel.

Optionally, the blank further includes a second end panel hingedly connected to the bottom panel along the second end edge, the second end panel being configured to form a second end wall in the set-up container. The blank further includes a second side panel hingedly connected to the bottom panel along the second side edge, the second side panel being configured to form a second side wall in the set-up container. The blank further includes a second corner flap hingedly connected to the first side panel along a second end edge thereof, the first corner flap being configured to fold into face-contacting relationship with the second end panel in the set-up container. The blank further includes a third corner flap hingedly connected to the second side panel along a first end edge thereof, the third corner flap being configured to fold into face-contacting relationship with the first end panel in the set-up container. The blank further includes a fourth corner flap hingedly connected to the second side panel along a second end edge thereof, the fourth corner flap being configured to fold into face-contacting relationship with the second end panel in the set-up container. The blank further includes a second corner locking member configured to secure a second corner in the set-up container, a third corner locking member configured to secure a third corner in the set-up container, and a fourth corner locking member configured to secure a fourth corner in the set-up container.

Optionally, the first corner locking member includes a bridge portion defined between the first fold line and a second fold line. The bridge portion has a height that is at least about equal to a thickness of the blank of sheet material.

Optionally, the first corner locking member further includes a generally-rectangular locking tab that is inserted into the first corner aperture in the set-up container.

Optionally, the first corner locking member further includes an intermediate portion disposed between the bridge portion and the locking tab. The intermediate portion is generally trapezoidal in shape. The intermediate portion is disposed in face-contacting relationship with an interior surface of the first end panel.

Optionally, the first slot has a generally elongated rectangular shape. The first slot has a width that is at least about equal to the thickness of the blank of sheet material, and a height that is at least about equal to a greatest width of the first corner locking member.

Within the scope of this application it is envisaged that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a top plan view of an exemplary blank of sheet material according to a first embodiment of the invention;

FIG. 1A is an enlarged view of the portion of the blank of FIG. 1 within the circular dash lines labeled 1A;

FIG. 2 is a perspective view of a container formed from the blank shown in FIG. 1;

FIG. 3 is an end view of the container of FIG. 2;

FIG. 4 is a side view of the container of FIG. 2;

FIGS. 5-10 show various steps in the construction of the container of FIG. 2.

DETAILED DESCRIPTION

Detailed descriptions of specific embodiments of trays and blanks are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the trays and blanks described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

In the embodiments detailed herein, the term “tray” or “carton” refers, for the non-limiting purpose of illustrating the various features of the invention, to a container for transporting, storing, and/or dispensing articles. It is contemplated that the teachings of the invention can be applied to various containers suitable for carrying a wide variety of articles.

Referring to FIG. 1, there is shown a first blank 10 for forming a tray or carton 90 (see FIGS. 2-4). The blank 10 is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, for example, to provide the trays described in more detail below.

In one or more embodiments, blank 10 can be formed from a paperboard, corrugated board, or cardboard in which one or both sides of the blank, is printed and/or treated with one or more coatings, such as for example, one or more waterproof coatings and/or one or more coatings designed to provide a smooth and/or visually-attractive surface (e.g., a white or other colored surface). In one or more embodiments, informational or promotional material such as, e.g., a brand name or logo, can be printed on a treated side.

Referring to FIG. 1, blank 10 is generally rectangular in shape and has a first or interior surface 6 and a second or exterior surface 8. Blank 10 is generally symmetrical about central longitudinal and transverse axes. In a set-up condition, the tray 90 forms an open-topped structure having a base or bottom wall, first and second side walls, and first and second end walls. Tray 90 has first, second, third, and fourth corners 70, 72, 74, 76 that are each secured via a corner locking arrangement.

Blank 10 includes a base panel 14. Base panel 14 is hingedly connected along a first side thereof to a first side panel 16 via longitudinal fold line 11. Base panel 14 is hingedly connected along a second, opposite side thereof to a second side panel 18 via longitudinal fold line 13. Base panel 14 is hingedly connected along a first end thereof to a first end panel 20 via transverse fold line 15. Base panel 14 is hingedly connected along a second, opposite end thereof to a second end panel 22 via transverse fold line 17. First side panel 16 is hingedly connected along a first end thereof to a first corner flap 24 via transverse fold line 19. First side panel 16 is hingedly connected along a second, opposite end thereof to a second corner flap 26 via transverse fold line 21. Second side panel 18 is hingedly connected along a first end thereof to a third corner flap 28 via transverse fold line 23. Second side panel 18 is hingedly connected along a second, opposite end thereof to a fourth corner flap 30 via transverse fold line 25. Transverse fold lines 19 and 23 may be substantially collinear with one another and with transverse fold line 15. Transverse fold lines 21 and 25 may be substantially collinear with one another and with transverse fold line 17.

A first corner locking member 32 is struck in part from first corner flap 24 and in part from first side panel 16. A second corner locking member 34 is struck in part from second corner flap 26 and in part from first side panel 16. A third corner locking member 36 is struck in part from third corner flap 28 and in part from second side panel 18. A fourth corner locking member 38 is struck in part from fourth corner flap 30 and in part from second side panel 18. First corner locking member 32 is configured to cooperate with a first slot 40 that is struck from a portion of first end panel 20 adjacent to first corner flap 24. Second corner locking member 34 is configured to cooperate with a second slot 42 that is struck from a portion of second end panel 22 adjacent to second corner flap 26. Third corner locking member 36 is configured to cooperate with a third slot 44 that is struck from a portion of first end panel 36 adjacent to third corner flap 28. Fourth corner locking member 38 is configured to cooperate with a fourth slot 46 that is struck from a portion of second end panel 22 adjacent to fourth corner flap 30.

Each of the first, second, third, and fourth corner locking members 32, 34, 36, and 38 can be substantially identical to one another; thus a description of first corner locking member 32 serves as a description of the other corner locking members. Similarly, each of the first, second, third, and fourth slots 40, 42, 44, 46 can be substantially identical to one another; thus a description of first slot 40 serves as a description of the other slots. First corner locking member 32 may be generally trapezoidal in shape. First corner locking member 32 is hingedly connected to first corner flap 24 via a transverse fold line 27 which defines an outermost end edge of first corner locking member 32. The length of fold line 27 defines a greatest width W1 of first corner locking member 32. Cut lines 56, 58 extend from opposite sides of fold line 27 towards first side panel 16 and define side edges of first corner locking member 32. In the illustrated embodiment, cut lines 56, 58 angle toward one another slightly until they intersect fold line 19 while the portions 60, 62 of cut lines 56, 58 hat extend into first side panel 16 are parallel to one another. A transverse cut line 64 in first side panel 16 extends between cut line portions 60, 62 and defines an innermost end edge of first corner locking member 32. First corner locking member 32 includes a bridge portion 50 that is defined between fold line 27 and a transverse fold line 29 that extends between cut lines 56 and 58. Bridge portion 50 has a height H1 (defined by the distance between fold lines 27 and 29) that is preferably about equal to, or slightly greater than, a thickness of blank 10. The portion of first corner locking member 32 that is struck from first side panel 16 (i.e., the portion defined between cut line portions 60 and 62, and between fold line 19 and cut line 64) forms a generally rectangular locking tab 54. Locking tab 54 has a height H2 (defined by the distance between fold line 19 and cut line 64) that is preferably about equal to, or slightly greater than, about twice the thickness of blank 10. An intermediate portion 52 of first corner locking member 32 is defined between bridge portion 50 and locking tab 54.

First slot 40 is sized and positioned so as to receive first corner locking member 32 therethrough when the tray 90 is assembled. Slot 40 has a generally elongated rectangular shape. Slot 40 has a width W2 that is preferably about equal to or slightly greater than the thickness of the blank 10. Slot 40 has a height H3 that is preferably about equal to or slightly greater than the greatest width W1 of first corner locking member 32.

Turning to the construction of the tray 90 as illustrated in FIG. 2, the tray 90 can be formed by a series of sequential folding operations. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements.

Blank 10 is positioned with its interior surface 6 facing up as shown in FIG. 1. Referring to FIG. 5, first end panel 20 is rotated inwardly about fold line 15 toward interior surface 6 of bottom panel 14 and into a substantially perpendicular relationship with bottom panel 14. Second end panel 22 is rotated inwardly about fold line 17 toward interior surface 6 of bottom panel 14 and into a substantially perpendicular relationship with bottom panel 14.

Referring to FIG. 6, first side panel 16 is rotated inwardly about fold line 11 toward interior surface 6 of bottom panel 14 and into a substantially perpendicular relationship with bottom panel 14. Second side panel 18 is rotated inwardly about fold line 13 toward interior surface 6 of bottom panel 14 and into a substantially perpendicular relationship with bottom panel 14.

Referring to FIG. 7, first corner locking member 32 is folded back about fold line 27 toward interior surface 6 of first corner flap 24. Referring to FIG. 8, first corner flap 24 is folded inwardly about fold line 19 toward the exterior surface 8 of first end panel 20, and first corner locking member 32 is inserted through first slot 40. Referring to FIG. 9, the interior surface 6 of first corner flap 24 is brought into face-contacting relationship with the exterior surface 8 of first end panel 20. Referring to FIG. 10, first corner locking member 32 is folded toward the interior surface 6 of first end panel 20. The exterior surface 8 of intermediate portion 52 is brought into face-contacting relationship with the interior surface 6 of first end panel 20, and locking tab 54 is inserted into corner aperture 66 in first side panel 16. Corner aperture 66 is the exposed portion of the aperture that results from moving first corner locking member 32 and, in particular, locking tab 54, out of plane with first corner flap 24 and first side panel 16. This secures the first corner of tray 90, locking first corner flap 24 in place against first end panel 20. The remaining three corners of tray 90 are assembled and secured in the same manner, i.e., by inserting the second, third, and fourth corner locking members 34, 36, and 38 through respective second, third, and fourth slots 42, 44, 46, and then inserting their locking tabs into the corresponding corner aperture formed in the adjacent side wall. The above-described steps result in the formation of the completed tray 90 as shown in FIG. 2.

The configuration of the disclosed blank 10 and tray 90 may provide certain advantages over other hand set trays. In particular, the tray 90 is aesthetically pleasing and easy to assemble, folds up very tightly so as to provide clean interior and outer surfaces, provides superior corner strength, and produces a minimal amount of blank material waste. In addition, the amount of blank material needed to form blank 10 and the overall size or “footprint” of blank 10 are relatively small.

Exemplary embodiments of blanks and methods for forming containers are described above in detail. The apparatus and methods are not limited to the specific embodiments described herein, but rather, components of apparatus and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other containers and methods, and are not limited to practice with only the containers and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other container applications.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

What is claimed is:
 1. A container formed from a blank of sheet material, the container comprising: a bottom panel forming a bottom wall of the container; a first end panel extending upwardly from a first end edge of the bottom panel, the first end panel forming a first end wall of the container; a first side panel extending upwardly from a first side edge of the bottom panel, the first side panel forming a first side wall of the container, the first end panel, first side panel, and bottom panel together forming a first corner of the container; a first corner flap hingedly connected to the first side panel along a first end edge thereof, the first corner flap being disposed in face-contacting relationship with the first end panel; a first corner locking member securing the first corner, the first corner locking member being struck in part from the first corner flap and in part from the first side panel, wherein the first corner locking member is hingedly connected to the first corner flap along a first fold line, wherein the first corner locking member is inserted through a slot formed through the first end panel and into a first corner aperture formed through the first side panel, wherein the first corner aperture is formed by folding the first corner locking member out of plane with the first side panel.
 2. The container according to claim 1, wherein the container further comprises second, third, and fourth corner locking members securing respective second, third, and fourth corners of the container.
 3. The container according to claim 1, wherein the first corner locking member comprises a bridge portion defined between the first fold line and a second fold line, wherein the bridge portion has a height that is at least about equal to a thickness of the blank of sheet material.
 4. The container according to claim 1, wherein the first corner locking member further comprises a generally-rectangular locking tab that is inserted into the first corner aperture.
 5. The container according to claim 4, wherein the first corner locking member further comprises an intermediate portion disposed between the bridge portion and the locking tab, wherein the intermediate portion is generally trapezoidal in shape, wherein the intermediate portion is disposed in face-contacting relationship with an interior surface of the first end panel.
 6. The container according to claim 4, wherein the first slot has a generally elongated rectangular shape, wherein the first slot has a width that is at least about equal to the thickness of the blank of sheet material, and wherein the first slot has a height that is at least about equal to a greatest width of the first corner locking member.
 7. A blank of sheet material for forming a container, the blank comprising: a bottom panel having first and second opposing end edges and first and second opposing side edges extending between the end edges, the bottom wall panel being configured to form a bottom wall in a set-up container; a first end panel hingedly connected to the bottom panel along the first end edge, the first end panel being configured to form a first end wall in the set-up container; a first side panel hingedly connected to the bottom panel along the first side edge, the first side panel being configured to form a first side wall in the set-up container, the first end wall, first side wall, and bottom wall together forming a first corner in the set-up container; a first corner flap hingedly connected to the first side panel along a first end edge thereof, the first corner flap being configured to fold into face-contacting relationship with the first end panel in the set-up container; a first corner locking member configured to secure the first corner in the set-up container, the first corner locking member being struck in part from the first corner flap and in part from the first side panel, wherein the first corner locking member is hingedly connected to the first corner flap along a first fold line, wherein, in the set-up container, the first corner locking member passes through a slot formed through the first end panel and into a first corner aperture formed through the first side panel, wherein the first corner aperture results from folding the first corner locking member out of plane with the first side panel.
 8. The blank according to claim 7, wherein the blank further comprises: a second end panel hingedly connected to the bottom panel along the second end edge, the second end panel being configured to form a second end wall in the set-up container; a second side panel hingedly connected to the bottom panel along the second side edge, the second side panel being configured to form a second side wall in the set-up container; a second corner flap hingedly connected to the first side panel along a second end edge thereof, the first corner flap being configured to fold into face-contacting relationship with the second end panel in the set-up container; a third corner flap hingedly connected to the second side panel along a first end edge thereof, the third corner flap being configured to fold into face-contacting relationship with the first end panel in the set-up container; a fourth corner flap hingedly connected to the second side panel along a second end edge thereof, the fourth corner flap being configured to fold into face-contacting relationship with the second end panel in the set-up container; a second corner locking member configured to secure a second corner in the set-up container; a third corner locking member configured to secure a third corner in the set-up container; and a fourth corner locking member configured to secure a fourth corner in the set-up container.
 9. The blank according to claim 7, wherein the first corner locking member comprises a bridge portion defined between the first fold line and a second fold line, wherein the bridge portion has a height that is at least about equal to a thickness of the blank of sheet material.
 10. The blank according to claim 7, wherein the first corner locking member further comprises a generally-rectangular locking tab that is inserted into the first corner aperture in the set-up container.
 11. The blank according to claim 10, wherein the first corner locking member further comprises an intermediate portion disposed between the bridge portion and the locking tab, wherein the intermediate portion is generally trapezoidal in shape, wherein the intermediate portion is disposed in face-contacting relationship with an interior surface of the first end panel.
 12. The blank according to claim 10, wherein the first slot has a generally elongated rectangular shape, wherein the first slot has a width that is at least about equal to the thickness of the blank of sheet material, and wherein the slot has a height that is at least about equal to a greatest width of the first corner locking member. 